FIELD OF THE INVENTION
[0001] This invention relates generally to twist-on wire connectors and, more specifically,
to an on-the-go twist-on wire connector having an electrically conducting medium for
enhancing the current carrying capacity between the wire ends, which are located in
the twist-on wire connector.
CROSS REFERENCE TO RELATED APPLICATIONS
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
REFERENCETO A MICROFICHE APPENDIX
BACKGROUND OF THE INVENTION
[0005] The concept of on-the-go twist-on wire connectors for connecting the junction of
two or more wires together by twisting a housing around the ends of wires is old in
the art. Twist-on wire connectors are well known in the art and generally comprise
an outer open end housing with a tapered threaded interior. such as a spiral thread,
to permit a user to insert wires into the tapered threaded interior. To use a twist-on
wire connector. the user inserts the ends of electrical wires into the spiral threaded
cavity on the inside of the wire connector. The user then holds the wires in one hand
and with the other hand twists the wire connector. The twisting action pulls the wire
ends into a low resistance electrical contact with each other in one continuous motion
without the need for special tools.
[0006] If the twist-on wire connector is located in a wet location it is necessary to place
a waterproof sealant around the wire connector. In order to prevent water or moisture
from entering the connector and forming an oxidation layer over the ends of the wire,
the user can insert the entire wire connector or at least the wire ends into some
type of a waterproof potting compound. The compound may be either anon hardening or
a hardening compound. In either case the compound creates a waterproof capsule over
the junction ends of the electrical wires.
[0007] The prior art process is time consuming because it involves two separate steps as
well as the nuisance of having separate potting compounds and containers to hold the
potting compound.
[0008] A second generation improved twist-on wire connector exits where the wires can be
encapsulated and sealed in a twist on wire connector to prevent water or moisture
from entering the connector and is shown in my U.S. patents 5,113,037; 5,023,402 and
5,151,239. The second generation twist-on wire connectors permits the user in one
continuous action to simultaneously form the junction ends of wire leads into a low
resistance electrical connection that is surrounded by a waterproof sealant to form
either a waterproof covering around the junction ends of the wire leads or a water-resistant
covering over the ends of the electrical wires. These are two of the types of twist-on
wire connectors available for use in different environmental conditions.
[0009] Under certain dynamic conditions, such as vibration and shock, or large temperature
changes the wires in the twist-on wire connector can become loosened and thus lower
the integrity of the connection between the wires in the twist on wire connectors
by either increasing the electrical resistance or decreasing the contact area or both.
[0010] In my copending patent application SN.09/987,780 titled LOW TORQUE TWIST-ON WIRE
CONNECTOR filed 11/16/02 I disclose a third generation electrical twist-on wire connector
wherein the integrity of the low resistance electrical connection of the twist-on
wire connector is enhanced by placing a small amount of self-adhering lubricant in
the twist-on wire connector. Generally, to enhance the electrical conductivity between
wires one needs only a small amount of self-adhering lubricant to provide an enhanced
low resistance electrical connection. My copending application points out incorporating
a small amount of a self-adhering lubricant into the twist-on wire connector results
in an enhanced low resistance electrical connection between the wire ends.
[0011] In the Low Torque Twist-on Wire Connector I permit a user to form the ends of two
or more wire leads into a low resistance electrical connection by having the twist-on
wire connector contain a self adhering lubricant located along a portion of the interior
of the twist-on wire connector. In operation of a twist-on wire connector the wires
are drawn into the housing by a spiral thread through the twisting action of the wires
with respect to housing. As the wires are drawn into the spiral thread, the frictional
resistance to the rotation of the wires increases until the wires can no longer be
hand twisted into the wire connector. With use of a lubricant on the spiral threads
the wires, which are drawn into contact with the lubricant, one decreases the torque
resistance for the same number of turns without the lubricant. That is, the torque
resistance, which is a result of frictional resistance between the wires and the spiral
thread decreases. Consequently, the torsonial resistance decrease allows the wires
to be brought into further electrical contact through only hand tightening while at
the same time the radially compressive forces on the wires become greater by being
forced into a smaller volume thus ensuring a low resistance electrical connection
that remains stable over an extending period of time. Because only a small amount
of self-adhering lubricant is needed within the wire connector to provide an enhanced
low-resistance electrical connection problems of the self-adhering lubricant accidentally
coming into contact with the exterior housing of other twist-on wire connectors is
minimized even if caps are not used on the twist-on wire connectors.
[0012] While my aforedescribed low resistance electrical connector shows one how to enhance
electrical conductivity between two or more wires in a twist on wire connector without
the aid of tools the current carrying capacity between the wires in a twist-on wire
connector is primarily determined by the amount of surface contact area between the
ends of the wires which is increased as a result of forcing the ends of the wires
into a smaller volume and greater surface to surface contact. It is also known in
the art to enhance electrical conductivity between the ends of wires by surrounding
the electrical leads with a metal conductor such as molten solder or the like and
allowing the molten solder to solidify around the ends of the wires. The use of solder
or the like in twist on wire connectors is generally disliked not only because it
requires additional steps and time but it also makes the connection permanent.
[0013] One of the ongoing difficulties with the field use of twist-on wire connectors is
that in order not to have an inordinate number of different size twist-on wire connectors
one size twist-on wire connector is used for multiple wires of different sizes. A
typical twist-on wire connector generally lists usable wire combinations according
to the number of wires and the size of the wires. For example, a twist-on wire connector
might state the usable number of wire combinations as follows: 1 or 2 # 10wires ,
1 #10 wire with 1-3 # 14 wires, 1 # 10 wire with 1 or 2 # 12 wires, 2 # 10 wires with
1 # 14 wire, 1-4 # 12 wires, wires, 2 # 14 wires with 2-4 #16 wires, 2 # 12 wires
with 1-2 # 14 wires, 2 # 12 wires with 1 or 2 # 18 wires, 2-5 # 14 wires, 4-6 # 16
wires or 1 #16 wire with 4 # 18 wires. As a result of the number or wires used as
well as the variation of size of the wires used the surface contact area between wire
ends and consequently the current carrying capacity between the ends of the wires
varies in accordance with the size of the wire leads as well as the number of wire
leads. That is, if the contact area between the ends of the electrical wires is relatively
small a greater opportunity exists for exceeding the current carrying capacity of
the wire junction and overheating the junction. Conversely, if the contact area between
the ends of the electrical wire is relatively large thechances of exceeding the current
carrying capacity of the junction between the wires is reduced.
[0014] Still other connectors, which are used with aluminumwires have been filled with an
antioxidant paste for the purpose of preventing the formation of an oxidation layer
on the exterior surface of the aluminum wire since the aluminum oxide has high electrical
resistance which can cause the junction between the wires to overheat.
[0015] The present invention provides an improved on-the-go twist-on wire connector that
provides an electrical connection between the ends of wires with the electrical connection
having improved current carrying capacity even when used with wires of different sizes
or multiple wires and at the same time retaining the convenience of conventional twist-on
wire connectors.
[0016] The present invention provides an improved on-the-go twist-on wire connector that
in one embodiment contains multiple mediums, a first medium comprising an electrical
conductive material that is present around the ends of the wires to enhance the current
carrying capacity between the free ends of the wires and a second medium comprising
a topical non-electrical conductive material separate from the first medium with the
topical barrier extending over the electrical conductive material to maintain the
electrical conductive material in the closed end of the twist on wire connector.
SUMMARY OF THE INVENTION
[0017] Briefly the present inventions comprises an on-the-go twist-on wire connector for
enhancing the current carrying capacity of the electrical wires contained therein
with the housing having a closed end and an open end with a wire engaging coil located
in the closed end of the housing for bringing a plurality of wires into surface-to-surface
contact to provide a direct surface-to-surface electrical path for flow of electrical
energy therebetween. Located in the closed end of twist-on wire connector is a pressure
deformable wire adhereable electrical conducting medium with the conformable wire
adhereable electrical conducting medium conformable around the plurality of wire ends
as the plurality of wire ends are brought into surface-to-surface engagement with
the conformable electrical conducting medium thereby forming an indirect current path
between the wire ends while retaining the on-the-go ability of the twist-on wire connector
to form an electrical connection solely through twisting action.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018]
Figure 1 is a partial cutaway view showing a twist-on wire connector with two mediums
located therein;
Figure 2 is the twist-on wire connector of Figure 1 showing two wires located in electrical
communication with each other in the presence of an electrically conductive material;
Figure 3 is a sectional view of a twist-on wire connector substantially filled with
an electrically conducting medium;
Figure 4 shows a view of a wire penetrable cap of the wire connector of Figure 3
Figure 5 shows the wire connector of Figure 3 with two wires located in surface to
surface contact as in the presence of an electrically conducting medium; and
Figure 6 shows the wire connector of Figure 1 with conformable electrically conductive
medium in the spiral thread.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Figure 1 is a partial cutaway view showing an on-the-go twist-on wire connector 10
having an exterior surface with a plurality of longitudinally extending finger engaging
recesses 10a. Located inside a closed end 12 of wire connector 10 is a spiral thread
11 or wire engaging coil. Located on the opposite end of twist-on wire connector 10
is a wire penetrable end 13 for penetration of wires into a chamber 14 in twist-on
wire connector 10. In the embodiment shown a wire penetrable cap 15 extends over the
wire penetrable end 13 with cap 15 penetrable therethrough by flexing, punching or
the like. On-the-go twist-on wire connectors are noted for there ease of use since
the operator merely inserts a plurality of wires into the spiral thread of the wire
connector and twists the wire connector to bring the wire ends into surface to surface
contact with each other to create a current path from a surface contact area of one
wire end to a surface contact area of another wire end without the need for an additional
step such as securing the wire ends together with solder or the like. This in situ
formation of electrical connections is widely preferred since the electrical connections
can be quickly made.
[0020] Figure 1 shows the twist-on wire connector 10 in section with the converging end
14a of chamber 14 containing an electrically conductive wire adhereable material 17
that forms surface engagement with the electrically conducting ends of the wires inserted
therein. Extending over conductive wire adhereable material 17 is a topical barrier
layer of a viscous non-electrically conductive material 18 which extends over the
exposed end of the viscous electrically conductive material 17 located in the closed
end of chamber 14 to form an insulating cover. The use of viscous material allows
the material to be retained in the wire connector during use as well as provides a
flowable or wire conformable material that permits wires to be twisted therein without
forcing the material out of the connector. By use of a pressure flowable or wire conformable
material that is sufficiently viscous so as not to run out of the connector one can
maintain the electrically conductive material in the connector. In addition, by use
of a non-hardenable material in either the electrically conductive material or the
electrically non-conducting one can alter a connection to add or take out wires without
having to cut the wires and restrip the wire ends.
[0021] In order to appreciate the operation of the present invention reference should be
made to Figure 2 which shows the twist-on wire connect 10 of Figure 1 without a cap
on the end of the wire connector.
[0022] Figure 2 shows a first wire 21 having an exposed electrically conducting end 21a
and a second wire 22 having an exposed electrical conducting end 22a that have been
inserted into the wire penetrable end 13 and extended through the topical barrier
layer of viscous non-electrically conductive material 18 and into the viscous electrically
conductive material 17 in the closed end of the chamber 14. In the embodiment shown,
the electrical conducting wire ends 21a and 22a have been twisted into a low resistance
electrical connection thought the coaction of the spiral thread 11 with the ends of
the wires to produce a current path from wire end to wire end by bringing portions
of the surface areas of wire end 21a into pressure contact with portions of the surface
areas of wire end 22a. A portion of the wire end 21a and 22a are twisted into a low
resistance electrical connection to each other in the presence of a medium of the
viscous electrically conductive material 17 while a further portion of the wires are
maintained proximate each other in a medium of the non-electrically conductive material
18. Thus, in the embodiment shown, a path for current flow from wire end 21 to wire
end 22a is enhanced since not only can current flow from wire end 21a to wire end
22a based on surface to surface contact between the wire ends 21a and 22a but current
can also flow from wire end 21a to wire end 22a through the electrically conducting
medium 17. As a result, one minimizes the opportunity for the ends of the wires in
the twist-on wire connector to heat up when current flows though the ends of the wires
since the increased current path due to the electrical conductive medium provides
less resistance to electrical flow from wire to wire then if the electrical conductive
medium were not present.
[0023] Viscous wire adhering electrical insulation materials are known in the art and have
been used in twist on wire connectors such as shown in my U.S. patents U.S. patents
5,113,037; 5,023,402 and 5,151,239. In addition the use of an insulating material
a viscous electrical conducting wire adhering material can comprise a base having
electrically conductive particles such as carbon fibers or metal particles therein.
Electrically conductive viscous lubricants are known in the art and are conventionally
used in the bearings of equipment such as treadmills or the like in order to drain
off static electrical charges created by the rotating belt.
[0024] As evident from the wire connector 10 shown in Figure 2 by inserting a plug of flowable
electrically conducting medium 17 into the wire engaging coil 11 and placing a topical
barrier 18 of a flowable non-electrically conducting medium, which extends over the
plug of electrically conducting medium 17, one creates a chamber condition so that
when wire end 21a and 22a are inserted into the plug of electrically conductive material
17 it must first penetrate through the topical barrier of the non-electrically conductive
material 18 that forms a protective insulating cap over the end of the wire ends.
As shown in Figure 2 the electrically conductive medium 17 surrounds and clings to
the exposed surfaces of the wire ends 21a and 22a to form a supplemental low electrical
resistance path from wire end 21a to wire end 22a. In addition, the topical barrier
18 of the non-electrical conducting medium clings to the wire ends 21a and 22a to
provide a protective barrier.
[0025] Thus the present invention includes the method of forming a multi-medium encapsulated
wire connection by the steps of: Placing a first wire adhereable medium in a closed
end of a twist-on wire connector. Placing a second wire adhereable medium over the
first wire adhereable medium. Extending a plurality of wires through the second wire
adhereable medium into the first wire adhereable medium. Twisting the wires in the
presence of both the first wire adhereable medium and the second wire adhereable medium
to thereby form a low electrical resistance connection between the plurality of the
wires in the first adhereable medium with the low resistance electrical connection
comprising an electrical current path formed partly by the surface to surface contact
of the ends of the wires and partly by the electrical conducting medium in surface
contact with each of the plurality of wire ends. If the electrically conducting medium
is flowable one can twist the wires therein and the material deformably flows around
the wires without running out of the connector as the wires are twisted therein. Similarly,
if the electrically insulating material is deformably flowable the insulating material
flows around the wires to shield the wires from external effects without running out
of the wire connector.
[0026] Figure 3 shows a wire connector 10 in partial cross section. As the twist-on wire
connect of Figure 3 is identical to the twist on wire connector of Figure 1 the numbers
for identical parts are also the same. Twist-on wire connector 10 differs from the
twist-on wire connector of Figure 1 in that the plug of electrically conductive material
17 substantially fills the entire chamber 14 in connector 10. Located proximate the
end face 17a of plug of electrically conductive material 17a is a topical disk like
barrier of a self adhering electrically insulating material.
[0027] Figure 4 shows an end view of cap 15 usable with the present invention with the cap
15 including a set of pie shaped flexible flaps 15a that project toward the center.
The flaps 15a are sufficiently pliable so as to bend or flex inward as one inserts
a wire therethrough. Generally it is preferred that the flaps contain sufficient resiliency
so as to follow and engage the wire as the wire is inserted therethrough. Such caps
are more thoroughly shown and described in my U.S. patents 5,113,037; 5,023,402 and
5,151,239 and are herein incorporated by reference.
[0028] Figure 5 shows twist-on wire connector 10 with the electrically conductive material
17 substantially filing the twist-on wire connectors and the electrical leads 21 and
22 extending through the cap 15. In this embodiment the electrical conducting wire
adhering material encapsulates the exposed ends 21a and 22a of wire connector 10.
The wire ends 21a and 22a are in electrical communication with each other in the presence
of the electrical conducting medium 17, which in this embodiment extends partially
onto the insulation covering on wires 22 and 21. The topical barrier of wire adhering
medium 18 remains as a protective cover extending from side to side over the electrically
conductive material and is forced outward slightly 18a by the volume of material occupied
by the wire ends 21a and 22a. In this embodiment the twist-on wire connector contains
a plug of electrically conductive material that substantially encapsulates the ends
of the wires with the electrically insulating material located as a protective cover.
If the wire adhering medium comprises a water proof sealant one can provide a water
resistant and water proof connector.
[0029] In the event that the twist-on wire connector is used in an environment not requiring
insulating protection the topical layer of insulating material 18 could be eliminated.
However, in doing so one must ensure that the electrical conductive material is not
forced out of the connector and thereby cause an electrical short. While different
insulation values of the wire adhering medium are usable with the invention in most
cases it is desirable to have non-electrically conductive material having an insulation
value of at least equal to the insulated housing on the twist-on wire connector.
[0030] Figure 6 shows a wire connector 10 in partial cross section. As the twist-on wire
connect of Figure 6 is identical to the twist on wire connector of Figure 1 the numbers
for identical parts are also the same. In the embodiment shown in Figure 6 a plug
of electrically conductive wire adhereable material 17 is located in the closed end
of the wire connector 10. In this embodiment the topical insulating layer has been
dispensed with. With the use of an electrically conductive material one can rely on
the cap on the wire connector to retain the electrically conductive material in the
wire connector. In addition, limiting the amount of electrically conductive material
such that the unfilled volume V
1 of chamber 14 is larger than the volume of the wire ends that are inserted into the
wire connector can ensure that the electrically conductive wire adhereable material
is not forced out of the twist-on wire connector during the on-the-go formation of
an electrical junction between the wire ends in the wire connector. Consequently,
with sufficient unfilled volume one can use a twist-on wire connector without a cap
or without a topical insulating layer.
[0031] Where technical features mentioned in any claim are followed by reference signs,
those reference signs have been included for the sole purpose of increasing the intelligibility
of the claims and accordingly, such reference signs do not have any limiting effect
on the scope of each element identified by way of example by such reference signs.
1. A multi-medium twist-on wire connector comprising;
a housing, said housing having a closed end and a wire penetrable end;
a spiral tread located in the closed end of said housing, said spiral thread having
a chamber therein;
an electrically conductive material located in a closed end of the chamber;
a topical barrier of a non-electrically conducting medium extending over the electrically
conducting medium so that when a plurality of wires are inserted into the plug of
electrically conductive material they must first penetrate through the topical barrier
of the non-electrically conductive material.
2. The multi-medium twist-on wire connector of claim 1 wherein the electrically conductive
material comprise a viscous electrically conductive material having an electrically
conductivity of at least equal to an electrical conductivity of the plurality of wires
therein.
3. The multi-medium twist-on wire connector of claim 1 wherein the non-electrically conductive
medium has an insulation value of at least equal to an insulation value of the housing
on the twist-on wire connector.
4. The multi-medium twist-on wire connector of claim 1 wherein the topical barrier comprises
a moisture repellent barrier.
5. The multi-medium twist-on wire connector of claim 1 wherein the topical barrier comprises
a topical barrier layer that extends over an exposed face of the viscous electrically
conductive material so that when the plurality of wires are inserted into the wire
penetrable end and extended through the topical barrier layer and into the electrically
conductive material in the closed end of the chamber and are then twisted, a portion
of the wires are twisted into a low resistance electrical connection to each other
in the presence of a medium of the electrically conductive material while a further
portion of the wires are maintained proximate each other in a medium of the non-electrical
conductive material.
6. The multi-medium twist-on wire connector of claim 1 wherein the conductive material
comprises a non-liquid and non-hardenable material.
7. The multi-medium twist-on wire connector of claim 1 wherein the topical barrier of
non-electrically conductive material forms a pierceable wire conformable covering
over the electrically conductive material in the spiral thread.
8. The on-the-go method of forming an enhanced wire connection comprising:
placing a first non-hardenable wire adhereable medium in a closed end of a twist-on
wire connector;
placing a second medium over an exposed portion of the first wire adhetrable medium;
extending a plurality of wires through the second medium into the first wire adhereable
medium; and
twisting the wires in the presence of both the first wire adhereable medium and the
second medium to thereby form a low electrical resistance connection between the plurality
of the wires in the first adhereable medium.
9. The method of claim 8 wherein the first wire adhereable member comprises a viscous
material placed in a sidc-to-side condition in the closed end of the twist-on wire
connector.
10. The method of claim 8 wherein the step of placing the first non-hardenable wire adhereable
medium in a closed end of a twist-on wire connector comprises placing an electrically
conductive medium in the closed end of the twist-on wire connector so that at least
a portion of the low resistant electrical connection extends through the electrically
conductive medium.
11. The method of claim 10 wherein the step of placing a second adhereable medium over
the first non-hardenable wire adhercable medium comprises placing a non-clectrically
conductive material over the first adhereable medium with the non-electrically conducive
material having a volume less than a volume of the non-hardenable material and the
adhereable electrically conductive medium occupies a portion of a volume of the chamber
in the wire connector such that an unfilled volume V1 of the chamber is larger than a volume of the plurality of wires that are inserted
into the wire connector to ensure that the neither the first non-hardenable medium
or the second adhereable medium is forced out of the twist-on wire connector during
the on-the-go formation of an electrical junction between the wires in the wire connector.